MEL Composites has reinforced its partnership with T cnico Solar Boat through the successful hull infusion of the S o Gabriel 01, an 8m long, 2.4m wide, hydrogen-powered hydrofoiling vessel, for the Monaco Energy Boat Challenge 2026. The project underscores the growing role of advanced composites in enabling lightweight, high-stiffness structures for next-generation sustainable marine platforms.

The hull represents the most technically complex structure undertaken by the team to date, requiring a customized vacuum infusion strategy to meet demanding performance targets. MEL Composites applied precision infusion expertise to achieve an optimal balance between weight reduction, structural stiffness, and hydrodynamic efficiency critical parameters for hydrofoiling vessels operating under high dynamic loads.

The S o Gabriel 01 pushed the limits,  said Eduardo Galofre, CEO, Mel Composites.  We worked closely with the team to engineer a structure capable of supporting a hydrofoiling hydrogen propulsion system, where every layer, every fibre, and every resin flow had to perform flawlessly.

• To support the infusion process, MEL recommended and provided a fully integrated composites materials solution tailored to the vessel s performance requirements. The bespoke package included:
• Sicomin InfuGreen 810 epoxy resin a bio-based, DNV-GL approved marine-grade formulation optimized for vacuum infusion processes. This low-viscosity resin enables precise wet-out and is ideal for complex laminate structures.
• Aircell high performance PVC foam core materials selected for excellent compression resistance and low density, ensuring high stiffness to weight ratios in sandwich construction a key factor in the performance of hydrofoils and hulls.
• Complete range of vacuum infusion consumables including vacuum bags, sealant tapes, tubing, fittings, breather and peel ply fabrics, ensuring consistent infusion, traceability and simplified procurement.

Mel Composites has been a key partner in transforming this ambitious concept into reality,  said Joao Simao, Team Leader, T cnico Solar Boat. Their experience and precision engineering enabled us to build a hull that s not only lightweight but capable of withstanding the forces generated during hydrofoiling a crucial step as we
move toward international competition next year. The project embodies the team s mission to accelerate sustainable innovation in marine mobility.